US10500823B2 - Active ester curing agent compound for thermosetting resins, flame retardant composition comprising same, and articles made therefrom - Google Patents

Active ester curing agent compound for thermosetting resins, flame retardant composition comprising same, and articles made therefrom Download PDF

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US10500823B2
US10500823B2 US15/772,848 US201615772848A US10500823B2 US 10500823 B2 US10500823 B2 US 10500823B2 US 201615772848 A US201615772848 A US 201615772848A US 10500823 B2 US10500823 B2 US 10500823B2
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carbon atoms
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composition
phosphorus
epoxy
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US20180326708A1 (en
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Andrew Piotrowski
Joseph Zilberman
Sergei V. Levchik
Meng Zhang
Eran Gluz
Kali Ananth Suryadevara
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ICL IP America Inc
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/26—Layered products comprising a layer of synthetic resin characterised by the use of special additives using curing agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/38—Layered products comprising a layer of synthetic resin comprising epoxy resins
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
    • C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
    • C08G59/40—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the curing agents used
    • C08G59/4007—Curing agents not provided for by the groups C08G59/42 - C08G59/66
    • C08G59/4071—Curing agents not provided for by the groups C08G59/42 - C08G59/66 phosphorus containing compounds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
    • C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
    • C08G59/40—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the curing agents used
    • C08G59/42—Polycarboxylic acids; Anhydrides, halides or low molecular weight esters thereof
    • C08G59/4246—Polycarboxylic acids; Anhydrides, halides or low molecular weight esters thereof polymers with carboxylic terminal groups
    • C08G59/4269—Macromolecular compounds obtained by reactions other than those involving unsaturated carbon-to-carbon bindings
    • C08G59/4276—Polyesters
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
    • C08G63/68—Polyesters containing atoms other than carbon, hydrogen and oxygen
    • C08G63/692—Polyesters containing atoms other than carbon, hydrogen and oxygen containing phosphorus
    • C08G63/6924—Polyesters containing atoms other than carbon, hydrogen and oxygen containing phosphorus derived from polycarboxylic acids and polyhydroxy compounds
    • C08G63/6926—Dicarboxylic acids and dihydroxy compounds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
    • C08J5/241—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using inorganic fibres
    • C08J5/244—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using inorganic fibres using glass fibres
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
    • C08J5/249—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs characterised by the additives used in the prepolymer mixture
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/49—Phosphorus-containing compounds
    • C08K5/51—Phosphorus bound to oxygen
    • C08K5/53—Phosphorus bound to oxygen bound to oxygen and to carbon only
    • C08K5/5313—Phosphinic compounds, e.g. R2=P(:O)OR'
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L63/00—Compositions of epoxy resins; Compositions of derivatives of epoxy resins
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L67/00—Compositions of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Compositions of derivatives of such polymers
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00—Printed circuits
    • H05K1/02—Details
    • H05K1/03—Use of materials for the substrate
    • H05K1/0313—Organic insulating material
    • H05K1/032—Organic insulating material consisting of one material
    • H05K1/0326—Organic insulating material consisting of one material containing O
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00—Printed circuits
    • H05K1/02—Details
    • H05K1/03—Use of materials for the substrate
    • H05K1/0313—Organic insulating material
    • H05K1/0353—Organic insulating material consisting of two or more materials, e.g. two or more polymers, polymer + filler, + reinforcement
    • H05K1/0373—Organic insulating material consisting of two or more materials, e.g. two or more polymers, polymer + filler, + reinforcement containing additives, e.g. fillers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat
    • B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2457/00—Electrical equipment
    • B32B2457/08—PCBs, i.e. printed circuit boards
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2363/00—Characterised by the use of epoxy resins; Derivatives of epoxy resins
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2201/00—Properties
    • C08L2201/02—Flame or fire retardant/resistant
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/01—Dielectrics
    • H05K2201/0104—Properties and characteristics in general
    • H05K2201/012—Flame-retardant; Preventing of inflammation

Definitions

  • the present invention relates to the field of flame retardants, specifically phosphorus-containing flame retardants for electronic applications such as printed circuit boards.
  • thermosetting resins are widely used in both industrial and consumer electronics because of, among other things, their chemical resistance, mechanical strength and electrical properties.
  • thermosetting resins can be used in electronics as protective films, adhesive materials and/or insulating materials, such as interlayer insulating films.
  • the thermosetting resins must provide ease of handling and possess certain physical, thermal, electrical insulation and moisture resistant properties.
  • thermosetting resins having a low dielectric loss tangent, while maintaining a sufficiently low dielectric constant can possess a desirable combination of properties for electronic applications, especially in situations requiring increased signal speed and frequency.
  • thermosetting resins can be flammable.
  • different approaches have been made to impart the desired level of flame resistance to thermosetting resins, such as epoxy resins, such approaches entailing the employment of either halogen-free flame retardant compounds or halogen-containing flame retardant compounds.
  • Halogenated compounds are now undergoing additional scrutiny, and the various non-halogenated compounds available are difficult to formulate to provide acceptable properties. It would be desirable to provide the desired level of flame retardancy and acceptable properties such as high glass transition temperature (Tg) and high thermal stability to a thermosetting resin, such as an epoxy resin, while still maintaining a suitable combination of properties for electronic applications.
  • Tg glass transition temperature
  • thermosetting resins such as epoxy resins
  • an active ester curing agent for thermosetting resins such as epoxy resins
  • thermosetting resins such as epoxy resins
  • epoxy resins which cured epoxy resins can be employed in electronic applications while imparting high thermal resistance and thermal stability, high adhesive force, low water absorbance, low dielectric loss tangent, and simultaneously, a sufficiently low dielectric constant.
  • many phosphorus-containing flame retardants react with epoxy resins with the formation of highly polar hydroxyl groups. For this reason, it is difficult to achieve good electrical properties in the cured products.
  • most of the known flame retardants for epoxy resins are monofunctional or bifunctional, thus impairing the cross-linking density of the cured resin, which is finally reflected in a reduced glass-transition temperature.
  • the present invention provides phosphorus-containing flame retardants which are used as polyfunctional curing agents, resulting in a combination of highly satisfactory flame-retarding, mechanical and electrical characteristics in the cured products. These compounds are phosphorus-containing aromatic polyesters. When they are used as curing agents, it is possible to reduce the formation of undesirable hydroxyl groups during the curing reaction.
  • the use of the curing agents of the invention enables an increase in the crosslinking density of the epoxy resin cured articles since these curing agents act as polyfunctional curing agents which have many reactive ester groups per molecule. As a result of their use, the glass transition temperature is high and the material is useful as an electrical insulating material.
  • the invention further provides epoxy resin compositions containing the said phosphorus-containing flame-retardant polyfunctional curing agent compounds that exhibit excellent fire retardant, mechanical and electrical properties.
  • active ester curing agent compound can be used interchangeably with “curing agent for epoxy resins”, “epoxy curing agent”, “curing agent for epoxy”, “epoxy resin curing agent” and “curing agent”, and the like.
  • X is a bivalent aromatic hydrocarbon group containing from 6 to about 12 carbon atoms, and which includes the non-limiting examples of phenylene groups, naphthalene groups, biphenylene groups, etc., which groups may optionally include a substituent bonded to the aromatic ring, such as an alkyl group or alkoxyl group containing up to 6 carbon atoms, or X is a bivalent linear or branched alkylene group of from 1 to 8 carbon atoms, or a bivalent linear or branched alkenylene group of from 2 to about 8 carbon atoms,
  • the phosphorus-containing flame-retardant polyfunctional curing agent can comprise a mixture of different structures of the general formula (I), e.g., the mixture can comprise wherein at least 50 wt % of the general formula (I) structures, and preferably more than 70 wt % of the general formula (I) structures are such that Y is chosen from moieties (i) and (ii) as noted above, with the remaining different structures of the general formula (I) being such that Y is chosen from the (iii) moiety noted above.
  • the compound of the formula (I), as described herein, can function both as a flame retardant and as a curing agent for curing thermosetting resins, such as epoxy resins, as described herein.
  • FIG. 1 is a graph of the dynamic viscosity (open circles) profile of B-stage prepreg containing Composition A of Example 11, at a ramp rate (filled circles) of 5° C./min in a rheometer under continuous controlled strain and normal force conditions.
  • FIG. 2 is a graph of rheology curves of overlays of storage modulus (G′—open circles), loss modulus (G′′—filled circles) and complex viscosity (
  • FIG. 3 is a graph of DMA measurement of Tg for the laminate (3° C./min) containing Composition A.
  • FIG. 4 is a graph of the TGA measurement of T d for the laminate containing Composition A (10° C./min).
  • the present invention is directed to compound(s), which can concurrently function as a flame retardant and an active ester curing agent(s) compound for thermosetting resins, such as epoxy resins, which cured epoxy resins can be employed in electronic applications while maintaining high thermal resistance and thermal stability, high adhesive force, low water absorbance, low dielectric loss tangent, and simultaneously, a sufficiently low dielectric constant.
  • thermosetting resins such as epoxy resins, which cured epoxy resins can be employed in electronic applications while maintaining high thermal resistance and thermal stability, high adhesive force, low water absorbance, low dielectric loss tangent, and simultaneously, a sufficiently low dielectric constant.
  • the compound(s) which function as the active ester curing agent compound(s) for thermosetting resins, such as epoxy resins, when reacted with epoxy resins, produce products which do not have or almost do not have hydroxyl groups such as secondary hydroxyl groups, thus preventing the high water absorption and higher dielectric constant of conventional curing systems, which when reacted with epoxy produce products which contain such secondary hydroxyl groups.
  • polyfunctional curing agents providing a high degree of crosslinking density that results in an exceptionally high Tg and excellent thermal stability.
  • Some more specific embodiments of the compound(s) which can be used as the curing agent compound for curing thermosetting resins, such as epoxy resins, is a compound of the general formula (I) as described above.
  • R 1 can be of the general formula:
  • R 2 is as defined above.
  • R 1 can be an alkyl of from 1 to about 4 carbon atoms, more specifically selected from methyl or ethyl.
  • X can be of the general formula:
  • X can be a divalent linear or branched alkylene group of from 1 to 8 carbon atoms, more specifically from 1 to about 4 carbon atoms, most specifically selected from the group consisting of methylene, ethylene, isopropylene and butylene.
  • X can be a divalent linear or branched alkenylene group of from 2 to 8 carbon atoms, more specifically from 2 to about 4 carbon atoms, most specifically selected from the group consisting of ethenylene, propenylene and isopropenylene.
  • Y can be of the general formula:
  • Y can be of the general formula:
  • n can be of from 1 to about 100, more specifically from 1 to about 15, and most specifically from 1 to about 7.
  • n can be 1, provided that R 1 is of the general formula:
  • R 2 is as defined above.
  • the compound(s) which can be used as the curing agent compound for curing thermosetting resins such as epoxy resins (e.g., the active ester curing agent for epoxy resins described herein) can be a phosphorus-containing compound of the general formula (I) such as those having at least three reactive groups per molecule, wherein at least two of the reactive groups are active ester groups. More preferably the phosphorus-containing compounds of the general formula (I) are those having at least four reactive groups per molecule, while the number of active ester groups is at least three.
  • compounds of the general formula (I) as described herein may also be used as a non-reactive additive, such as when used with other thermosetting systems, e.g., other than epoxy.
  • compounds of the general formula (I) noted herein can be used as a charring agent to provide an insulating layer of char at elevated temperatures for thermosetting formulations.
  • active ester refers to an aromatic ester that can react with an epoxy group according to the following scheme:
  • DOPO-HQ 10-(2′,5′-dihydroxyphenyl)-9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide
  • R* is an alkyl or aryl group containing up to 12 carbon atoms
  • the curing agent acts as a polyfunctional curing agent, a cured article therefrom has a high crosslink density which is reflected in an exceptionally high Tg. Since the formation of highly polar and thermally liable hydroxyl groups is minimized during the curing, a cured article has a high thermal stability and low dissipation factor. Since the curing agent has a bulky structure, crystallization of the molecule chain is prevented and the solubility of the polyester curing agent in an epoxy resin composition is very good. In contrast to the compounds of EP 1 416 007 A1, the compounds of the present invention also provide excellent flame retardancy.
  • compositions and/or formulations obtainable by reacting, blending or mixing compound(s) of the general formula (I), with other components such as a thermosetting resin to form various ignition resistant compounds, compositions or formulations useful in various applications such as prepregs, laminates, coatings, molding articles and composite products.
  • Another embodiment herein is directed to phosphorus-containing epoxy resin curable formulations comprising (i) compound(s) of the general formula (I), (ii) an epoxy resin or a mixture of epoxy resins, (iii) optionally, a co-crosslinker, (iv), optionally, a curing catalyst, and (v) optionally, a Lewis acid.
  • a curable flame-resistant epoxy resin composition comprising (i) the compound of the general formula (I), (ii) optionally, a benzoxazine-containing compound, (iii) a crosslinkable epoxy resin or a blend of two or more epoxy resins having more than one epoxy group per molecule, (iv) optionally a co-crosslinker and, (v) optionally, a curing catalyst, to obtain a curable flame-resistant epoxy resin composition.
  • Such curable flame-resistant epoxy resin compositions may be used to make prepregs, which prepregs may be used to make laminates and circuit boards useful in the electronics industry.
  • the epoxy resin composition may also be used to coat metallic foils, such as copper foils, to make resin-coated copper foils for so called build-up technology.
  • thermosetting system epoxy and curing agents
  • Epoxy Resin Composition Epoxy Resin Composition
  • the compound(s) of the general formula (I) described herein, as well as in one embodiment and combinations thereof, may be used as one component of a curable (crosslinkable) phosphorus-containing flame-resistant epoxy resin composition.
  • the curable phosphorus-containing flame-resistant epoxy resin composition comprises (i) the compound(s) of the general formula (I) described herein, (ii) at least one epoxy resin such as those selected from halogen-free epoxies, phosphorus-free epoxies, and phosphorus-containing epoxies, and mixtures thereof, including, but not limited to, DEN 438, DER 330 Epon 164 (DEN and DER are trademarks of The Dow Chemical Company), epoxy functional polyoxazolidone-containing compounds, cycloaliphatic epoxies, GMA/styrene copolymers, and the reaction product of DEN 438 and DOPO resins; and optionally (iii) at least one co
  • the curable phosphorus-containing flame-resistant epoxy resin composition optionally may contain at least one additional crosslinkable epoxy resin or a blend of two or more epoxy resins other than and different from component (ii) above.
  • the curable phosphorus-containing flame-resistant epoxy resin composition may also optionally contain at least one curing catalyst and at least one inhibitor. All of the above components may be blended or mixed together in any order to form the curable phosphorus-containing flame-resistant epoxy resin composition.
  • the curable phosphorus-containing flame-resistant epoxy resin compositions prepared according to the present invention made by reacting a mixture of compound(s) of the general formula (I) described herein, an epoxy resin, and optionally another co-crosslinker (i.e. another curing agent); may be used to make prepregs, laminates and circuit boards useful in the electronics industry and as a phosphorus-containing flame-resistant epoxy resin composition to coat metallic foils for so called build-up technology as described above.
  • R 4 is a substituted or unsubstituted aromatic, aliphatic, cycloaliphatic or heterocyclic group having a valence of “p”, where “p” preferably has an average value of from 1 to less than about 8.
  • polyepoxide compounds useful in the present invention include the diglycidyl ethers of the following compounds: resorcinol, catechol, hydroquinone, 4,4′-biphenol, bisphenol A, bisphenol AP (1,1-bis(4-hydroxylphenyl)-1-phenyl ethane), bisphenol F, bisphenol K, phenol-formaldehyde novolac resins, alkyl-substituted phenol-formaldehyde resins, phenol-hydroxybenzaldehyde resins, cresol-hydroxybenzaldehyde resins, dicyclopentadiene-phenol resins, dicyclopentadiene-substituted phenol resins, tetramethylbiphenol, and any combinations thereof.
  • polyepoxide compounds useful in the present invention include a diglycidyl ether of bisphenol A having an epoxy equivalent weight (EEW) between 177 and 189 sold by The Dow Chemical Company under the trademark D.E.R. 330; and halogen-free epoxy-terminated polyoxazolidone resins, phosphorus-containing epoxy compounds; cycloaliphatic epoxies; and copolymers of glycidyl methacrylate ethers and styrene.
  • EW epoxy equivalent weight
  • Preferred polyepoxide compounds include epoxy novolacs, such as D.E.N. 438 or D.E.N. 439 (trademarks of The Dow Chemical Company); cresole epoxy novolacs such as QUATREX 3310, 3410 and 3710 available from Ciba Geigy; Epon 164 from Momentive, trisepoxy compounds, such as TACTIX 742 from Ciba Geigy; epoxidized bisphenol A novolacs, dicyclopentadiene phenol epoxy novolacs; glycidyl ethers of tetraphenolethane; diglycidyl ethers of bisphenol-A; diglycidyl ethers of bisphenol-F; and diglycidyl ethers of hydroquinone.
  • epoxy novolacs such as D.E.N. 438 or D.E.N. 439 (trademarks of The Dow Chemical Company)
  • cresole epoxy novolacs such as QUATREX 3310, 3
  • the most preferred epoxy compounds are epoxy novolac resins (sometimes referred to as epoxidized novolac resins, a term which is intended to embrace both epoxy phenol novolac resins and epoxy cresol novolac resins).
  • Epoxy novolac resins (including epoxy cresol novolac resins) are readily commercially available, for example under the trade names D.E.N. (trademark of The Dow Chemical Company), and QUATREX and TACTIX 742 (trademarks of Ciba Geigy).
  • Preferred compounds of the type mentioned above have an epoxy equivalent between 150-400 and most preferably from 160-300 and a molecular weight above 500 and most preferable between 700-2500.
  • the polyepoxide useful in the present invention is preferably substantially free (or completely free) of bromine atoms, and more preferably substantially free (or completely free) of halogen atoms.
  • polyepoxides that are useful in the present invention and that are substantially free of halogen atoms are the phosphorus-containing epoxy resins such as those which are the reaction products of an epoxy compound containing at least two epoxy groups and a reactive phosphorus-containing compound such as 3,4,5,6-dibenzo-1,2-oxaphosphane-2-oxide (DOPO), or 10-(2′,5′-dihydroxyphenyl)-9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO-HQ).
  • DOPO 3,4,5,6-dibenzo-1,2-oxaphosphane-2-oxide
  • DOPO-HQ 10-(2′,5′-dihydroxyphenyl)-9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide
  • the amount of epoxy in the compositions described herein i.e., the curable phosphorus-containing flame-resistant epoxy resin compositions, the thermoset composition and the hybrid composition, are such that in the final formulation of the epoxy, any optional phosphorus-containing epoxy based on compound(s) of the general formula (I) described herein in the amounts described herein, and any other components in the amounts described herein or known to those skilled in the art, is such that the total phosphorus content of the composition is from 1 weight percent to about 5 weight percent, more specifically from about 2 to about 3.5 weight percent.
  • the amount of epoxy to be commensurate with such other components, so as to have the final phosphorus content as described above.
  • the amount of such phosphorus-containing epoxy in the final composition can vary from 10-90 parts, preferably 20-80 parts and most preferably from 30-50 parts, based on 100 parts of epoxy resin.
  • the amounts of epoxy resin described herein can in one non-limiting embodiment be equal to the amounts of the thermoplastic resin in the thermoplastic composition described herein, the thermoset resin in the thermoset composition described herein and the combined amount of the resins in the hybrid composition described herein.
  • the effective flame-retardant amount of the compound(s) of the general formula (I) described herein which can be used as the compound for the curing epoxy resin herein, in the curable epoxy resin composition described herein, will vary, depending on the specific epoxy resin and the specific compound being employed, as well as the specific parameters of processing as are known by those skilled in the art.
  • the effective flame-retardant amount of compound(s) of the general formula (I) described herein which can be used for curing the epoxy resin is from about 10 to about 150 parts by weight per 100 parts of the epoxy resin, more specifically from about 30 to about 100 parts by weight per 100 parts of the epoxy resin and most specifically from about 50 to about 70 parts by weight per 100 parts of the epoxy resin.
  • compositions herein will contain from 1% to about 5% phosphorus in the final composition.
  • the above stated amounts of compound(s) of the general formula (I) described herein can be the amounts of compound(s) of the general formula (I) described herein used in any of the epoxy resin compositions, the thermoset composition, and the hybrid composition, described herein.
  • phosphorus-containing flame-resistant epoxy resin compositions may be formed by blending (i) compound(s) of the general formula (I) described herein, (ii) at least one crosslinkable epoxy compound, and optionally (iii) at least one co-crosslinker, as well as any of the other optional components described herein; or in another embodiment, the phosphorus-containing flame-resistant epoxy resin compositions may be formed by blending (i) an epoxidized compound(s) based on compounds of the general formula (I) described herein, at least one crosslinkable phosphorus-containing compound, and (iii) at least one co-crosslinker, as well as any of the other optional components described herein.
  • the phosphorus-containing flame-resistant epoxy resin compositions may, optionally, contain at least one crosslinkable epoxy resin other than the crosslinkable phosphorus-containing compounds in (ii) above.
  • crosslinkable in crosslinkable phosphorus-containing compound, is understood to be a phosphorus-containing epoxy compound which has more than 2 epoxy functionalities, as would be understood by those skilled in the art.
  • any number of co-crosslinking agents may optionally also be used.
  • Suitable co-crosslinkers that may optionally be present in combination with the phosphorus-containing epoxy compounds according to the present invention include, for example, multifunctional co-crosslinkers as are known to those skilled in the art.
  • the co-crosslinkers include, for example, copolymers of styrene and maleic anhydride having a molecular weight (M w ) in the range of from 1,500 to 50,000 and an anhydride content of more than 15 percent.
  • M w molecular weight
  • Commercial examples of these materials include SMA 1000, SMA 2000, and SMA 3000 and SMA 4000 having styrene-maleic anhydride ratios of 1:1, 2:1, 3:1 and 4:1, respectively, and having molecular weights ranging from 6,000 to 15,000, which are available from Elf Atochem S.A.
  • hydroxyl-containing compounds such as those represented by the following Formula (III):
  • R 5 is a hydrogen or an alkyl group having from 1 to 20, preferably from 1 to 10, and more preferably 1 to 5 carbon atoms and “q” is an integer of from 0 to 20, preferably from 1 to 10, and more preferably from 2 to 5.
  • co-crosslinker that is suitable in the compositions described herein is an active ester phenolic resin with the general formula (IV):
  • R 6 is hydrogen, an aliphatic moiety of from 1 to 10 carbon atoms, or a phenyl or a substituted phenyl
  • R 7 is an aliphatic moiety of from 1 to 4 carbon atoms, or a phenyl or a substituted phenyl group.
  • EPICLON HPC-8000-65T available from DIC corporation, Japan.
  • R 8 and R 9 may be, independently and separately, the same or different hydrogen, an allyl group from 1 to about 10 carbon atoms such as methyl, a 6 to 20 carbon atom aromatic group such as phenyl, or a 4 to 20 carbon atom cycloaliphatic group such as cyclohexane.
  • the co-crosslinker is present in an amount to crosslink of less than 50 percent of the stoichiometric amount needed to cure the thermosetting resin, such as the epoxy resin, and is more preferably less than about 40% of the amount needed to cure the thermosetting resin, such as the epoxy resin, and is most preferably less than about 35% of the amount needed to cure the thermosetting resin, such as the epoxy resin.
  • any of the curable compositions of the present invention described herein may comprise a curing catalyst.
  • suitable curing catalyst materials (catalyst) useful in the present invention include compounds containing amine, phosphine, ammonium, phosphonium, arsonium or sulfonium moieties or mixtures thereof.
  • Particularly preferred catalysts are heterocyclic nitrogen-containing compounds.
  • tertiary amines that may be used as catalysts are those mono- or polyamines having an open-chain or cyclic structure, which have all of the amine hydrogen replaced by suitable substituents such as hydrocarbyl radicals, and preferably aliphatic, cycloaliphatic or aromatic radicals.
  • amines examples include, among others, 1,8-diazabicyclo(5.4.0)undec-7-en (DBU), methyl diethanolamine, triethylamine, tributylamine, dimethyl benzylamine, triphenylamine, tricyclohexyl amine, pyridine and quinoline.
  • DBU 1,8-diazabicyclo(5.4.0)undec-7-en
  • Preferred amines are trialkyl, tricycloalkyl and triaryl amines, such as triethylamine, triphenylamine, tri-(2,3-dimethyl cyclohexyl)amine, and alkyl dialkanol amines, such as methyl diethanol amines and trialkanolamines such as triethanolamine.
  • tertiary amines for example amines that in aqueous solutions give a pH less than 10 in aqueous solutions of 1 M concentration, are particularly preferred.
  • Especially preferred tertiary amine catalysts are benzyldimethylamine and tris-(dimethylaminomethyl)phenol.
  • alkyl-substituted imidazoles 2,5-chloro-4-ethyl imidazole; and phenyl-substituted imidazoles, and mixtures thereof.
  • N-methylimidazole 2-methylimidazole; 2-ethyl-4-methylimidazole; 1,2-dimethylimidazole; 2-methylimidazole and mixtures thereof.
  • 2-phenylimidazole is 2-phenylimidazole.
  • the amount of curing catalyst used depends on the molecular weight of the catalyst, the activity of the catalyst and the speed at which the polymerization is intended to proceed.
  • the curing catalyst is used in an amount of from 0.01 parts per 100 parts of resin (p.h.r.) to about 1.0 p.h.r., more specifically, from about 0.01 p.h.r. to about 0.5 p.h.r. and, most specifically, from about 0.1 p.h.r. to about 0.5 p.h.r.
  • a Lewis acid is also employed in any of the curable epoxy resin compositions of the present invention described herein, especially when the catalyst is particularly a heterocyclic nitrogen-containing compound.
  • the Lewis acids useful in the present invention include for example one or a mixture of two or more halides, oxides, hydroxides and alkoxides of zinc, tin, titanium, cobalt, manganese, iron, silicon, aluminum, and boron, for example Lewis acids of boron, and anhydrides of Lewis acids of boron, such as boric acid, metaboric acid, optionally substituted boroxines (such as trimethoxyboroxine), optionally substituted oxides of boron, alkyl borates, boron halides, zinc halides (such as zinc chloride) and other Lewis acids that tend to have a relatively weak conjugate base.
  • Lewis acids of boron such as boric acid, metaboric acid, optionally substituted boroxines (such as trimethoxyboroxine), optionally substituted oxides of boron, alkyl borates, boron halides, zinc halides (such as zinc chloride) and other Lewis acids that tend to have a relatively weak conjug
  • the Lewis acid is a Lewis acid of boron, or an anhydride of a Lewis acid of boron, for example boric acid, metaboric acid, an optionally substituted boroxine (such as trimethoxy boroxine, trimethyl boroxine or triethyl boroxine), an optionally substituted oxide of boron, or an alkyl borate.
  • a Lewis acid of boron for example boric acid, metaboric acid, an optionally substituted boroxine (such as trimethoxy boroxine, trimethyl boroxine or triethyl boroxine), an optionally substituted oxide of boron, or an alkyl borate.
  • the most preferred Lewis acid is boric acid.
  • the Lewis acids and amines can be combined before mixing into the formulation or by mixing with the catalyst in situ, to make a curing catalyst combination.
  • the amount of the Lewis acid employed is preferably at least 0.1 mole of Lewis acid per mole of heterocyclic nitrogen compound, more preferably at least 0.3 mole of Lewis acid per mole of heterocyclic nitrogen-containing compound.
  • the curable compositions of the present invention may optionally have boric acid and/or maleic acid present as a cure inhibitor.
  • the curing agent is preferably a polyamine or polyamide.
  • the amount of cure inhibitor will be known by those skilled in the art.
  • the curable compositions of the present invention may also optionally contain one or more additional flame retardant additives including, for example, red phosphorus, encapsulated red phosphorus or liquid or solid phosphorus-containing compounds, for example, “EXOLIT OP 930”, EXOLIT OP 910 from Clariant GmbH and ammonium polyphosphate such as “EXOLIT 700” from Clariant GmbH, a phosphite, or phosphazenes; nitrogen-containing fire retardants and/or synergists, for example melamines, melem, cyanuric acid, isocyanuric acid and derivatives of those nitrogen-containing compounds; halogenated flame retardants and halogenated epoxy resins (especially brominated epoxy resins); synergistic phosphorus-halogen-containing chemicals or compounds containing salts of organic acids; inorganic metal hydrates such as Sb 2 O 3 , Sb 3 O 5 , aluminum trihydroxide and magnesium hydroxide, such as “ZEROGEN 30”
  • the phosphorus-containing flame retardants are preferably present in amounts such that the total phosphorus content of the epoxy resin composition is from 0.2 wt. percent to 5 wt. percent.
  • the curable compositions of the present invention may also optionally contain other additives of a generally conventional type including for example, stabilizers, other organic or inorganic additives, pigments, wetting agents, flow modifiers, UV light blockers, and fluorescent additives. These additives can be present in amounts of from 0 to 5 wt. percent and are preferably present in amounts of less than 3 wt. percent.
  • the flame-resistant epoxy resin is preferably free of bromine atoms, and more preferably free of halogen atoms.
  • compositions described above are useful for making coating formulations, encapsulation, composites, and adhesives, molding, bonding sheets, and laminated plates.
  • the compositions of the present invention can be used to make composite materials by techniques well-known in the industry, such as by pultrusion, molding, encapsulation, or coating.
  • a coating formulation may comprise (i) compound(s) of the general formula (I) described herein (ii) a solid epoxy resin, and (iii) a hardener such as an amine or phenolic hardener. The amounts of hardener will be known by those skilled in the art.
  • the present invention is particularly useful for making B-staged prepregs, laminates, bonding sheets, and resin-coated copper foils by well known techniques in the industry.
  • Thermosetting Composition (Thermosetting Composition)
  • thermosetting composition is obtainable by blending (i) compound(s) of the general formula (I) described herein with (ii) at least one thermosetting system.
  • thermosetting systems are epoxy, polyurethane, polyisocyanates, benzoxazine ring-containing compounds, unsaturated resin systems containing double or triple bonds, polycyanate ester, bismaleimide, triazine, bismaleimide and mixtures thereof.
  • thermoset resin compositions herein can contain any of the components and or ranges of amounts of such components described herein for the curable epoxy resin composition or the hybrid compositions, and vice-versa, and of the thermoset resin composition, i.e., any of the components and or amounts of the components of the thermoset composition described herein can be used in any of the epoxy compositions, or the hybrid compositions described herein.
  • Partial curing as used herein can comprise any level of curing, short of complete cure, and will vary widely depending on the specific materials and conditions of manufacture as well as the desired end-use applications.
  • the article herein can further comprise a copper foil.
  • the article can comprise a printed circuit board.
  • an FR-4 laminate which comprises a prepreg and/or laminate of the invention.
  • a printed circuit board comprising an FR-4 laminate, wherein the FR-4 laminate comprises a prepreg or laminate of the invention.
  • a process for making a laminate that contains any of the compositions described herein comprises impregnating the respective composition(s) into a filler material, e.g., a glass fiber mat to form a prepreg, followed by processing the prepreg at an elevated temperature and/or pressure to promote a partial cure to a B-stage and then laminating two or more of said prepregs to form said laminate.
  • a filler material e.g., a glass fiber mat
  • said prepreg can be used in the applications described herein, e.g., printed circuit boards.
  • any of the compositions described herein are useful for making a prepreg and/or laminate with a good balance of laminate properties and thermal stability, such as one or more of high T g (i.e. above 130° C.), a T d of 330° C. and above, a t 288 of 5 minutes and above, a flame resistance rating of V-0, good toughness, and good adhesion to copper foil.
  • T g i.e. above 130° C.
  • T d 330° C. and above
  • t 288 of 5 minutes and above
  • V-0 flame resistance rating of V-0
  • good toughness good adhesion to copper foil.
  • the T d has become one of the most important parameters, because the industry is changing to lead-free solders which melt at a higher temperature than traditional tin-lead solders.
  • compositions described herein can be used in other applications, e.g., encapsulants for electronic elements, protective coatings, structural adhesives, structural and/or decorative composite materials, in amounts as deemed necessary depending on the particular application.
  • thermosetting resins such as epoxy resins.
  • the method of making the active ester curing agent of the compound(s) of the general formula (I) described herein can comprise the following general reaction mechanism:
  • Acetic anhydride is both solvent and reagent. It is used between 1 to 10 molar excess and most preferably 2 to 5 molar excess with respect to DOPO-HQ. The reaction is carried out at 170° C.-260° C. and most preferably 190° C.-240° C. for a period of 1-16 hours and most preferably 5-8 hours.
  • DOPO-HQ (3.2 g, 10 mmol) and pyridine (0.8 g, 10 mmol) were mixed together in 50 mL of acetone/dioxane.
  • Isophthaloyl dichloride (1.0 g, 5 mmol) in 20 mL of acetone was added dropwise. The suspension was heated to reflux temperature, and a homogenous solution formed. After 4 h, solvents were removed under vacuum. The leftover white solid was washed with water and dried under vacuum. The final product was a white solid.
  • 1 H NMR 300 MHz, Acetone-d 6 , ppm
  • ⁇ 8.69-6.90 (m, 26H).
  • 31 P NMR (121 MHz, Acetone-d 6 , ppm) ⁇ 28.
  • HPLC showed di-isophthaloyl ester of DOPO-HQ 74%, other higher oligomers 18%, low-molecular weight compounds 8%.
  • DOPO-HQ-isophthaloyl-ester (pentamer mixture): DOPO-HQ (71.9 g, 221.6 mmol) and pyridine (25 mL, 310.5 mmol) were mixed together in 200 mL of chloroform. Isophthaloyl dichloride (30.0 g, 147.8 mmol) in 50 mL of chloroform was added dropwise. The suspension was heated to reflux temperature, and a homogenous solution formed. After 3 h, the solution was cooled down to room temperature and washed with 0.5 M HCl aq solution and saturated brine. The organic layer was collected and dried over sodium sulfate. Solvents were removed under vacuum. The final product was a white solid.
  • DOPO-HQ (4.8 g, 15.0 mmol) and pyridine (2.0 mL, 24.6 mmol) were mixed together in 50 mL of chloroform.
  • Terephthaloyl dichloride (2.0 g, 9.8 mmol) in 20 mL of chloroform was added dropwise. The suspension was heated to reflux temperature for 3 h. The insoluble solids were filtered out, and the solution was washed with 0.5 M HCl aq solution and saturated brine. The organic layer was collected and dried over sodium sulfate. Solvents were removed under vacuum. The final product was a white solid.
  • 1 H NMR 300 MHz, Chloroform-d, ppm) ⁇ 9.00-6.78 (multiple H).
  • 31 P NMR (121 MHz, Chloroform-d, ppm) ⁇ 32.5-34, 18-19. HPLC showed trimer 7.2%, pentamer 29%, heptamer and other higher oligomers 60%.
  • DOPO-HQ-malonyl-ester DOPO-HQ (6.9 g, 21.3 mmol) and pyridine (2.5 mL, 28.4 mmol) were mixed together in 50 mL of chloroform. Malonyl dichloride (2.0 g, 14.2 mmol) in 20 mL of chloroform was added dropwise. The suspension was heated to reflux temperature for 6 h. The insoluble solids were filtered out, and the dark green solution was washed with 0.5 M HCl aq solution and brine. The organic layer was collected and dried over sodium sulfate. Solvents were removed under vacuum. The final product was a yellow foam. 31 P NMR (121 MHz, Chloroform-d, ppm) ⁇ 32-33, 20. HPLC showed trimer 27%, pentamer 14%, heptamer and other higher oligomers 47%.
  • the product consisted of phosphorus-containing oligomeric terephthalates of formula (I), The product contained 7.6% DOPO-HQ-monoacetate and DOPO-HQ-acetate-terephthalate, 13% unreacted DOPO-HQ-Diacetate and 78.4% oligomers (HPLC area %) with the major fractions being trimers, pentamers and heptamers. The product contained 7.2% wt. phosphorus. The principal constituents of the product were identified by means of LC-MS (Table 1).
  • LC-MS analyses were conducted on a Dionex, UHPLC, Ultimate 3000, equipped with a PDA 200-450 nm UV detector.
  • the column used was Phenomenex, Kinetex, Phenyl-Hexyl 100A, 250 ⁇ 4.6 mm, 5 ⁇ .
  • the vacuum was gradually increased from about 30 mm Hg to 1 mm Hg towards the end.
  • the resulting, very viscous, product was poured onto an aluminum plate. Solidification occurred almost instantly.
  • the product consisted of phosphorus-containing oligomeric isophthalates of formula (I).
  • the final solid product was ground and dried at 137° C. under vacuum to eliminate the residual acetic acid.
  • TGA 1% 299° C., 5% 322° C., 10% 374° C.
  • the product contained 7.2% wt. phosphorus and was completely soluble in MEK (methyl ethyl ketone).
  • the temperature was increased gradually to 250° C. over a period of 3 h. During this period, the vacuum was gradually increased from about 30 mbar to 1 mbar towards the end. The resulting, very viscous, liquid product was poured onto an aluminum plate. Solidification occurred almost instantly as the product cooled.
  • the final solid product obtained in a quantitative yield, had a light-brown color and contained 3.3% DOPO-HQ-monoacetate and DOPO-HQ-acetate-isophthalate, 13% unreacted DOPO-HQ-Diacetate and 83.1% oligomers (HPLC area %), with major fractions of trimers, pentamers and heptamers. Most of the constituents of the product were identified by LC-MS (Table 2).
  • TGA 1% 304° C., 2% 334° C., 5% 365° C., 10% 400° C.
  • the phosphorus content in the product was 6.8%.
  • the total content of acetic acid in the product dried under vacuum was about 0.25% (GC head-space).
  • the product had excellent solubility in MEK.
  • Up to 60% of oligomeric DOPO-HQ isophthalate of Example 7 was dissolved in MEK at 55° C. No precipitation was observed upon cooling to room temperature.
  • catalyst such as potassium or sodium acetates enabled to achieve the same results as without a catalyst but using milder conditions, such as a lower temperature and higher vacuum (30 mbar instead of 1 mbar) that are more suitable for the scale-up.
  • DOPO-HQ-diacetate was synthesized from DOPO-HQ and acetic anhydride. This product has very limited solubility in MEK.
  • composition A synthesized in Example 2 was explored as a co-curing agent for the epoxy laminate application.
  • the composition A together with phenolic Novolac was used to cure multi-functional epoxy resins DEN 438 and EPON 164. All the materials information is listed in Table 4.
  • the solids content was maintained at 66.67% with the addition of MEK/Dowanol (80/20) solvent mixture.
  • a varnish formulation was prepared therefrom which had a phosphorous content of 2.7% and the composition contents are shown in Table 5.
  • a glass fabric (17 inches X 36 inches) was continuously passed through a trough containing the varnish and through squeeze rolls such that a uniform coating was obtained. Sections of the coated fabric were hanged in the hood overnight for slow evaporation of solvent. Prepregs were made by drying the resin coated glass fabric in a preheated air circulated oven at 160° C. for 4′30′′ (four minutes and thirty seconds), which gave a resin flow less than 20.0%. Also, the resin content was controlled to be over 50-55%, which is determined through the difference in weight between the glass fabric and the prepreg.
  • the prepreg gel time was determined by collecting the fusible, thermoplastic resin by crushing the prepreg in a zip-lock bag. The collected resin was placed on the hot-plate at 171° C. and the gel time determined. The prepreg properties are shown in Table 6 below:
  • a circular stack of 4 prepregs with a diameter of 25 mm was placed between disposable aluminum (Al) plates to study the rheological behavior of the B-stage prepreg by electrically heating the resin to 200° C. at 5° C./min in an AR2000ex Rheometer.
  • a continuous controlled strain condition within the linear viscoelastic region of the prepreg was maintained along with the normal force control that accounts for volume changes occurring in the resin with change in temperature.
  • FIG. 1 shows the complex viscosity profile of the prepreg with rise in temperature of the B-staged resin system in an oscillatory testing mode.
  • FIG. 2 shows the overlay curves for the storage modulus (G′), loss modulus (G′′) and complex viscosity (
  • the press was maintained at 220 psi and 195° C. isothermally for 90 minutes.
  • the laminate showed a good resin flow and the thickness of the final laminate was close to 1.3 mm (without copper).
  • the laminate was rated as a borderline V-0 with a maximum burn time of 7 seconds by following ASTM D3801-10 standard using an Atlas UL-94 burning chamber (V-0 being the highest possible rating).
  • the glass transition temperature (Tg) of the multilayer laminate was determined to be 192° C. by Dynamic Mechanical Analysis (DMA) in a single-cantilever mode at a ramp rate of 3° C./min.
  • the thermal decomposition temperature of the composite at 5 weight % loss is 416° C. as measured by Thermogravimetric Analysis (TGA) at a heating rate of 10° C./min in an inert atmosphere of nitrogen.
  • PCT Pressure Cooker Test
  • composition A synthesized in Example 8 was explored as a co-curing agent for the epoxy laminate application.
  • the composition A together with phenolic Novolac was used to cure multi-functional epoxy resins DEN 438 and EPON 164. All the materials information is listed in Table 4.
  • the solids content was maintained at 65-66% with the addition of MEK/Dowanol (80/20) solvent mixture.
  • a varnish formulation was prepared therefrom which had a phosphorous content of 2.4% and the composition contents are shown in Table 7.
  • a varnish was formulated from material prepared for sampling purposes to confirm its performance in a glass filled laminate.
  • the varnish was prepared using a MEK/Dowanol (80/20) solvent mixture.
  • the coated panels were hung to air dry overnight. After drying the four 18′′ ⁇ 30′′ panels were cut into 8.5 inch squares prior to “B” staging at 165° C. in a forced air oven.
  • the laminate was made using 8 plies of each prepreg between 2 sheets of 35 ⁇ m copper foil.
  • Table 9 Formulation of DOPO-HQ-diacetate from comparative Example 1 (synthesis) at 2.7% P in final epoxy varnish with Dowanol as solvent. This product was difficult to formulate due to limited solubility.

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